Reflector unit



July 8, 1941.

C. H. MAHONEY ETAL REFLECTOR UNIT Filed Feb. 20, 1939 UharlesHMd/MneVVi'lliam5.Brian/;

Patented July 8, 1941 REFLECTOR UNIT Charles Hallam Mahoney and WilliamStanley Brian, Owensboro, Ky., assignors to Ken-Rad Tube & Lamp Corp.,Owensboro, Ky., a corporation of Delaware Application February 20, 1939,Serial No. 257,492

9 Claims.

This invention relates to reflecting units of the type generally knownas reflector buttons which include a refractory lens and a mirrorsuitably assembled to be handled as a unit for gasket at the time ofmanufacture of the unit, against atmo'sphericattack in such a Way thatno gases or moisture can reach the reflecting surface therebymaintaining the original high reflecting light rays when mounted insigns or reflecting power of the polished surface and, other supports.consequently, materially increasing the life of One of the principalobjections todevices the unit as a whole. In that connection, the ofthis type is that the metallic mirror or reinvention contemplates themanufacture of a flector soon becomes tarnished in use, and thereflector button wherein the seal, such as sulefiiciency of the unit isconsequently impaired. 10 phur free rubber is applied by precisionmachine The lens itself being made of glass, and usually methodswhichaiford no opportunity for poor mounted in a protective casing orshell remains workmanship which would result in a poor seal unchangedand seldom becomes damaged, and, depending upon the skill of aparticular worktherefore, ordinarily lasts much longer than the man.Where seals of cement or the like have reflector because it is notsubject to deteriorabeen previously used, the operator may apply tion bythe action of the elements or by moisture the cement poorly so thatopenings are left in or gases. However, on the contrary, the reflectorthe seal win some cases the operator may even at the inner end of thelens becomes gradually fail to put in the cement at all, or suflicientcetarnished by oxidation from aim-gases or moisment, according to hisjudgment. Moreover, ture entering the unit, or from condensation. theapplication ofcement or like sealing me- This is particularly true whena silver reflector diums by individual operators is a tedious and isused. Metallic silver when polished is the best chance operation.available reflector but in most cases due to its A further object of theinvention is to protendency. to tarnish or corrode it has been largevidea construction which readily lends itself to ly replaced by other andcheaper metals such standard manufacturing practices thereby makaspolished chromium or polished aluminum ing it possible to economicallyproduce a unit of which, however, are of much lower reflective thistype, that is, of the type wherein the reefilciency. r flector ishermetically sealed at the time of A primary object of the invention isto seal assembly so that at no time after it leaves the the reflectorin' the shell or cup in a novel way factory is it necessary todisassemble any of the to therebyprevent deterioration of the reflectorparts with the consequent danger of admitting surface.- While it hasbeen hereto-fore proposed moisture or gases which will affect thereflector. to enclose the mirror or reflector in a shell, A generalobject of the invention is, thereand, also, in some cases to use a seal,neverthefore, to provide a reflector unit which is so conless, cement ofone type or another has been structed when it is first made as to givelonger used for a seal and, moreover, so far as is known, life andhigher efficiency in use and in which no attempt has been previouslymade to herthe original efficiency of the reflecting surface meticallyseal the mirror under pressure. Ceis maintained even where silver isemployed. ment and other seals heretofore employed are With the aboveand other objects in view not permanent because as the atmospherictemwhich will more readily appear as the nature of perature changes, theglass lens, the metal cup the invention is better understood, the sameand the cement, each having different coeflicients consists in the novelconstruction, combination of expansion, change in their relative sizes,and, and arrangement of parts hereinafter more fully as a result at sometemperature the seal is described, illustrated and claimed. broken. Inaddition, the small amount of air A preferred and practical embodimentof the sealed in with the mirror will also expand or present inventionis shown in the accompanying contract with a change in temperaturethereby drawing in which: tending to break the seal and set-up abreathing Figure 1 is a vertical sectional view of one action whichtends to draw in some contaminatform of unit constructed in .accordancewith the ing gas or' substance. Therefore, previous atpresent invention.tempts'to effect a seal are not sumciently ef- Figure 2 is a fragmentarysectional view ilfective to perform the intended function. lustrating astep in the making of the unit.

Accordingly, the present invention has pri- Figure 3 is a verticalsectional view of a unit marily in view a construction wherein thereembodying 'a modified form of construction. flect'or is hermeticallysealed, with a resilient Figure 4 is another vertical sectional view 11-lustrating a further modification of the invention.

Similar reference characters designate corresponding parts throughoutthe several figures of the drawing.

Referring to Figure 1, it will be observed that the unit includes in itsorganization an outer shell or cup designated generally as I. This shellis preferably metal stamping and, therefore, impervious to moisture,gases and other elements which would tend to act adversely on areflecting surface. The upper edge of the shell I is provided with aflange 2 which assists in mounting the unit in a suitable support suchas the surface of a sign or the like. ,Within the shell I there isprovided a pair of spacing rings 3 and 4 which in effect provideabutment means for limiting the inward movement of the lens. These ringsare so arranged as to clamp between the adjacent edges thereof, theperipheral edge portion of a suitable polished reflector or mirror 5.The lower edge of the ring 3 rests on the bottom wall of the casing Iand the upper edge of the ring 4 constitutes an abutment or stop for thelens 6.

The lens 6 is made of pressed or molded glass and its side wall isprovided with an annular offset rib I. The outer surface of the ribsnugly fits the inner surface of the shell, and, as

will be apparent from the drawing, this arrangement provides a spacebetween the body of the lens and the inner surface of the shell, oneside of said space being bounded by a shoulder formed by the rib. Inother words, the construction is such that the annular rib on thecollimating lens 6 cooperates with the shell to provide a cavity withinthe shell. This cavity is intended to receive a compressible sealingmedium 8. This medium may be of any material suitable for the purpose,such, for example, as a rubber sealing ring which may be convenientlyapplied or fitted to the lens before it is placed in the shell.

After the lens and sealing material are fitted in the shell, :acompression ring is placed in placed on the glass body of the lens so asto the cavity between the lens and the shell as shown in Figure 2. Thiscompression ring, designated generally as 9, includes a compressionflange orring I0 and a sealing flange II, and when placed in theposition shown in Figure 2 may be placed in a suitable compressing andsealing die whereby the entire ring 9 is forced into the cavity andagainst the sealing medium until the flange II abuts with the flange 2of the shell.

The flange II may then be welded to .the flange 2 to permanentlycompress the sealing material and also permanently lock the lensin theshell. As will be observed from Figure 2, the flange 2 of the shell maybe provided with suitable raised portions formed by pressing ordisplacing the metal of the flange to form lugs which assist in weldingthe flanges 2 and II together.

Under ordinary circumstances the sealing material 8 is compressed undera pressure of approximately 1500 pounds to the square inch therebyhermetically sealing the chamber'or space between the lower side of thelens and the metallic reflecting surface 5. It will thus be apparentthat with a. seal of this type the reflector -5 is effectively shieldedfrom attack by atmossilver as the reflector, or, on the other hand,

adequately protecting the polished surface of any metal of which thereflector may be made.

Figure 3 of the drawing illustrates a construction wherein the outershell la is intended to receive the spacing rings 30!. and 4a having thereflector 5a clamped therebetween as previously described. The lens 6ais provided with a shoulder Ia to form a cavity between the body of thelens and the inner surface of the shell. The said shell, however, isformed differently at its upper edge than the upper edge of the shell Ishown in Figure 1. That is to say, the upper edge 2a of the shell Ia,while having the flange portion thereof bent outwardly to form ashoulder for assisting in fitting the shell to a support, nevertheless,originally, said flange has the major portion thereof directed upwardlyas shown by the dotted lines 21) in Figure 3. When the flange is in thecondition shown by dotted lines it will be apparent that the shell Iamay receive the glass reflecting lens Ba having the sealing ring 8afitted thereto and abutting with the shoulder provided by the annularrib Ia. After the lens is placed in the shell so that the lower edge ofthe rib rests against the upper edge of the upper spacing ring, asealing ring I2 is placed against the otherwise exposed side of thesealing gasket 8a and then the portion 21) of the flange 2a is pressedor spun from the dotted-line position to the full-line position shown inFigure 3 thereby compressing the sealing gasket in final position. Theeffect of compressing the gasket 8a is to hermetically seal the chamberof the shell which houses the mirror or reflector 5a.

A further modification of the invention is shown in Figure 4 of thedrawing from which it will be observed that the shell 'Ib having thespacing rings 31? and 47) therein, and clamping the reflector 5btherebetween, is provided at its upper edge with an out-turned flange2c. The lens 6b is provided with an annular rib 1b which fits snuglywithin the inner surface of the shell lb. In this instance the sealinggasket 8b is engage the shoulder of the rib "Ib which is farthest fromthe mouth of the shell. In other words, the compressible sealing gasket8b is confined in the cavity or space bounded on opposite sides by thelens and the shell, and, also, by a shoulder of the rib and the upperedge of the spacing ring 4b. The outer shoulder of the annular rib 1b ofthe lens is engaged by a compression and locking ring t3 which pressesthe entire lens inwardly of the shell and effects com- .pression of thesealing ring by movement of the entire lens. When the ring I3 abuts withthe flange '20 at the upper edge of the shell these parts are "weldedtogether thereby securely holding the lens in the shell and at the sametime permanently maintaining the rubber sealing ring 812 undercompression thereby to effectually seal the chamber, in which thereflector 5b is mounted, from atmospheric attack.

In all of the constructions described, the resilient gasket such assulphur free rubber will maintain a gastight joint between the glasslens and the metal cup at any temperature regardless of the expansion orcontraction of any of the parts. Pressure alone, without the resilientgasket, would not insurea perfect seal at all temperatures to whichreflector buttons are exposed.

In contrast to previ'ouspractice, the present unit is completelyfinished when it leaves the machine.

For example, where cements are employed, between the cup and the lens,as previously'set .forth, the time necessary to neatly center the lensin the cup and the extra labor necessary to remove the particles ofcement from the exposed portions of the lens and cup, materially slow-upproduction and add to the cost. Moreover, where cements are employed,time is required for the cement to set. During this period the assemblymust be carefully held in special trays which take up factory space, andin addition the loading and unloading of the trays consume more time andlabor.

From the foregoing, it will be apparent that lens, and one of theshoulders of the rib onthe lens. This cavity receives the resilient compressible sealing material, and, on compression of said material eitherby movement of a compressor ring, or by the movement of the lens itself,the compressible sealing medium becomes permanently compressed, thus,hermetically sealing the reflector housing chamber of the shell from allweather conditions and gases which would have a tendency to impair theefliciency of the reflector surface. In all forms of the invention thecompression of the sealing medium is effected under high pressure, atthe time of manufacture, and the metallic and glass parts of the unitneed never be taken apart from the time they are finished at the factoryuntil theyv are installed at the point of use.

Without further description, it is believed that the features andadvantages of the invention will be readily apparent to those skilled inthe art, and it will, of course, be understood that changes in the form,proportion and minor details of construction may be resorted to, withoutdeparting from the spirit of the invention and scope of the appendedclaims.

We claim:

1. In a reflector unit, an outer shell closed at its back and having anopen mouth, a reflector within the shell, a lens having an annular rib,an annular member fitted within the shell and spacing the reflector fromthe lens, a second annular member fitted within the shell and heldbetween the reflector and the back of the shell, a resilient sealingmedium within the shell and engaging one shoulder of the rib, andannular means rigidly held at the mouth of the shell for permanentlymaintaining said sealing medium compressed to hermetically seal thereflector against atmospheric attack and to hold the lens in the shell,said rib and sealing medium being held between the first mentionedannular member and the said annular means rigidly held at the mouth ofthe shell.

2. A reflector unit, comprising, in combination, a tubular shell formedwith a closed end wall and an open mouth and of uniform interiordiameter from said wall to the mouth, a reflector within the shell, 2.lens including a cylindrical body having an annular rib of a diameter tofit within the shell below the open mouth thereof, an annular memberwithin the shell and spacing the reflector from the lens,'a secondannular member fitted within the shell between the reflector and theclosed end wall of the shell, said annular' members cooperating to limitinward movement of the lens, an annular compressible sealing gasketbetween the inner surface of the shell and the cylindrical body. of thelens and engaging one side of the annular rib of the lens, and annularmeans rigidly held at the mouth of the shellfor compressing the rib ofthe lens and the gasket together thereby to'seal the reflector againstinfiltration ,of gases or other destructive matter.

3. A reflector unit comprising, in combination, a lens having an annularrib presenting inner and outer shoulders, a shell for receiving thelens, a plurality of rigid spacing rings fitted within the shell forlimiting the inward movement of the lens, a reflector having itsperipheral edge held between said spacing rings; a compressible sealinggasket confined between the inner surface of the shell, the outersurface of the lens, and the outer shoulder of the rib on the lens; andmeans carried by the shell for maintaining said sealing gasketpermanently compressed within the aforesaid confining parts therebyhermetically to seal the reflector in the shell from atmospheric attack.

4. A reflector unit comprising, in combination, a shell open at one endand closed at the other, a reflector in the shell, a lens having anannular rib, abutment means within the shell for limiting inwardmovement of the lens and holding the reflector spaced from the lens, arubber sealing gasket surrounding the lens at the outer side of saidrib, means initially movable within the shell in a direction toward saidabutment means to compress said rubber gasket against said ribhermetically to seal the portion of the shell in which the reflector ismounted, and means for securing the last mentioned means to the shell.

5. A reflector unit comprising, in combination, a cup-like shell havinga flange at the mouth thereof, a lens body having an annular rib fittedin the shell, spacing rings within the shell for limiting the inwardmovement of the lens, a reflector having its peripheral portion heldbetween the adjacent inner edges of said spacing rings,'a compressiblesealing gasket confined in the cavity formed by the inner side of theshell, the outer side of the lens body and the shoulder formed at theouter side of the rib on the lens; and a sealing ring of angularcross-section having one flange thereof engaging and compressing saidsealing gasket and the other flange secured to the flange of the shell.

6. A reflector unit, comprising, in combination, a cup-like shell havinga flange at the mouth thereof, a lens body having an annular rib fittedin the shell, spacing rings within the shell for limiting the inwardmovement of the lens, a reflector having its peripheral portion heldbetween the adjacent edges of said spacing rings; a Icompressiblesealing gasket confined in the cavity formed by the inner side of theshell, the outer side of the lens body and the shoulder formed at theouter side of the rib on the lens; and a non-compressible sealing ringfitted in the space between the shell and the body of the lens, and saidflange on the shell being bent inwardly to engage said ring to force thesame against and compress the sealing gasket to hermetically seal thereflector against atmospheric attack and hold the lens in the shell.

7. A reflector unit comprising, in combination,

a cup-like shell having a flange at the mouth thereof, a lens includinga cylindrical body having an annular rib presenting opposite shouldersand fitted within the shell, a plurality of spacing rings within theshell for limiting inward move? ment of the lens, a reflector having itsperipheral edge portion held between adjacent edges of said spacingrings; a compressible sealing gasket located in the space defined by theinner surface of the shell, a portion of the outer surface of thecylindrical lens body, the inner shoulder of said annular rib and theouter edge of the outer spacing ring; and an annular element rigidlysecured to the flange of the shell and engaging the shoulder of the lensrib opposite that engaging the sealing gasket.

8. A reflector unit including a metallic shell closed at its bottom andopen at its mouth, a

flange projecting outwardly from the mouth of V the flange of the shelland welded to said flange to maintain said, rib and sealing mediumcompressed relative to said abutment means thereby hermetically to sealthe reflector against atmospheric attack.

9. A gas tight and moisture-proof reflector unit including a metallicshell closed at its bottom and open at its mouth, a reflector within theshell, a lens having an annular rib presenting opposite shoulders andfitted within the shell from the openmouth thereof, annular abutmentmeans in the shell for supporting the reflector, a ring for spacing theinner end of the lens from the reflector, said ring having its inneredge engaging the peripheral edge of the reflector, said annularabutment means and ring limiting the inward movement of the lens, acompressible sealing medium within the shell between the inner shoulderof the rib and the outer edge of said ring, and annular means se'curedto the mouth of the shell and engaging the outer shoulder of the rib tomaintain said sealing medium confined under pressure between the ringand the inner shoulder of the rib hermetically to seal the reflectoragainst atmospheric attack.

CHARLES I-IALLAM MAHONEY. WILLIAM STANLEY BRIAN.

